Cork board insulation and method of erecting the same



c. c. SCHRADER Fired Feb. 28, 195o Aug. 23, 1932.

CORK BOARD INSULATION AND METHOD OF EREOTING THE SAME Patented Aug. 23, 1932 UNITED STATES PATENT OFFICE CHARLES C. SCHRADER, OF LANCASTER, PENNSYLVANIA, ASSIGNOB TO ARMSTRONG CORK COMPANY, F LANCASTER, PENNSYLVANIA, A CORPORATION OF PENNSYL- vANIA v CORK BOARD INSULATION AND METHOD 0F ERECTING THE SLAllllEll Application led February 28, 1930. Serial No. 432,063.

This invention relates to a corkboard insulation and a method of erecting the same. In the erection of corkboard against a masonry, concrete or brick wall, as, for example, in the i construction of refrigerating rooms, the common practice is to apply a plaster coat to the inside surface of the wall, thus forming a plane surface to which the insulation is applied, followed 'by the use of an asphalt paint on the plaster to serve as a bond for securing the corkboard to the wall. Asphalt is also used on the corkboard itself. The asphalt on the board is applied by hot dipping, but since the wall is cold, the asphalt will congeal without forming a good key to the wall unless the' wall has been painted, as above stated. The great difficulty with this method of erection is the impossibility of getting adequate contact between the board and the wall throughout the areaJ of the board. However careful a plasterer is, the wall will have irregularities deeper than the paint coat. The 'asphalt dipon the board is, therefore, called upon to flow laterally along the board if these irregulari- 5 ties in the Wall are to be filled. The asphalt on the board hardens almost immediately upon contact with the painted wall. As a `result, contact is had, usually, at the high points only on the wall. Another difficulty is the failure of the film of asphalt paint in high walls. Due to the decreased contact area, the stress induced in the effective paint lm is frequently greater than it will bear. Where the wall is higherthan about 14 feet, additional mechanical support is usually supplied. Since some insulation walls have a height as much as feet, it will be seen that a ready means of erecting corkboard so that each block or slab will adhere firmly is a marked improvement over the method nowgenerally in vogue. v 4

I provide for applying a cementitious coating tb the surface of the board, placing the board against the base wall with the coating innermost, and permitting the coating to harden. Preferably, provision is made for` mechanically keying the board to the cementitiousv coating.' Ordinarily it will not be practicable to shape the surface of the corkboard so as to obtain such keying, first, for

the reason that the slabs are sawn from large blocks and a special shaping would involve additional operations, and second, because, as hereinafter stated, I prefer to use a corkboard whichis specially treated, and suchtreata ment is rendered more difficult with a nonplanar surface. I therefore preferably employ keys in the form of hangers which are secured to the corkboard and which have projecting portions embedded in the cementitious coating. For example, I may employ nails which are driven into the corkboard but left with their heads projecting a short distance, the heads being embedded in the cement.

-Ordinary corkboard is attacked by the free lime present in wet plaster. I therefore prefer to employ a corkboard which is adequately sealed against moisture penetration. In the copending application of Lester E. Cover, Serial No. 414,435, filed December 16, 1929, there is described and claimed a corkboard having its outer particles embedded in a` matrix, which matrix may extend to considerable depth and is eective for sealing the board against moisture and air infiltration,

and to which plaster will bond.n Such matrixy agents, such as soap, glue, clay or the like, l

may be employed. If an emulsion is used, the matrix should have a melting point below point. An asphalt'having a melting point of about F. will provesatisfactory. I preferably employ corkboard manufactured according tgt/he said Cover application.

l 212 F., as a low-,melting-point asphalt emulsies better than one -having a high melting In the accompanying drawing illustrating the present preferred embodiment of the invention, f

Figure lis a broken perspective view illustrating an insulation wall;

Figure 2 isa sectional view-showing the to the corkboard; and

Figure 3 is a view enlarged scale showing one of the hangers in the corkboard.

The insulating wall shown in Figure l comprises a base wa1l2 ofbrickwork, a layer 3 of plaster, a layer 4 of corkboard, a layer 5 `of corkboard', and a face coating 6 of asphalt orlthe like. In applying the layer 4 of corkboard to the base wall 2, each slab 7 of corkboard is first provided with hangers in the form of hook-like nails 8. Any desired number of these nails is driven into each slab of corkboard, the heads being allowed to project, as shown in the drawing. In order to preserve the nails against attack and to matrix seals the board against infiltration of air, and coupled with the coating on the projecting nail heads, gives protection to theentire surface.

yEach 'corkboard slab with its projecting' nails uppermost is fed lthrough a guide .10l

under a doctor blade 11 with a mass of Portland cement plaster P therebehind. This gives a coat 3W of wet plaster over the surface of the-corkboard, the projectingpheads of the binder nails 8 being embedded therein.

- The slab is then pushed against the wall and supported until the 'plaster dries. The plasteradheres readily to the base wall 2 and also adheres to the corkboard 4. This adherence -f is due not only to the resence of the hangers 8, but also to a enera adherence over the surface of the cork oard, which adherence may be enhanced by mechanical interlocking with pits or depressions in the surface.

v After .the layer 4 of corkboard has been put in place, t e layer 5 is applied in the usual fashion by applying as ha t to one surface of the slabs forming the ayer 5, pressing them against the 1 layer 4, while breaking joints, and driving nails 12 into the layer 4.

I have illustrated at 6 a facing coat which may be of asphalt or 'the like. In certain cases this may e omitted and the joints alone treated. If a single thickness wall is required, a coating maybe applied to the ex'- posed face of the layer 4, or the joints alone of this layer may be treated.

The plaster. layer emplo ed will generally be' about 1/2 inch thick, an the nails will be allowed to project about 3A ,ths of an inch. I

have successfully supported 12 inch by 36 inch slabs by employing six nails, but with nails of the ordinary type in very light corkboard, there is a tendency, when the cork is exposed to extreme test conditions, for the nails to cut through the cork. For this reason I prefer to use the fiat hook-like nails shown'in the drawing. Whatever type of nails be employed, theyTl may advantageously befformed of rustless or non-corroding material.

A great advantage of my invention that the corkboards may be placed against the wall and worked into position much more easily l than under the present method `where an asphalt paint is employed. In addition, there are substantially no void spaces between the corkboard andthe wall where moisture mayI condense. The invention is applicable to other types of corkboard, but revision should be made for 'sealing the cor against the attack of free lime in the plaster.

I have illustrated and described a present preferred form -of the invention. It will be understood, however, that this is by way of illustration only, and that the invention may be votherwise embodied or practiced withiny the scope of the appended claims. I claim: v

1. An insulating structure comprising a base, a hardened cementitious facing, corkboard over the facing, and tiesbedded in the facing1v1 nd extending into the corkboard.

2. insulating structure comprising a wall of brick or the like, a hardened cementitious facing, corkboard over the facing, and ties bedded in the facing and secured to the corkboard. l

3. An insulating structure -comprisin corkboard facing, bracing nails exten ing portions.

into the corkboard, the nails havin projecting outwardly from the corkoard and supports engaging the projecting portions of the nails.

4. An insulating structure comprising a i corkboard facing, hangers extending into the corkboard and having flattened top faces,

portions of the hangers projecting beyondV the corkboard, and supporting means engaging'said projecting portions.

5. An insulating structure comprising a i lcorkboard facing, hangers extending into the corkboard and having flattened top faces, portions of the hangers projecting beyond the corkboard, and supporting means engaging said projecting portions, said sup orting means engaging the surface of the corkboard.

6. An insulating structure comprising ay base, a hardened cementitious facing adherent thereto, and corkboard over the facing and in contact therewith, the corkboard constituting particles of cork, those particles in the corkboard adjacent the cementitious facing being embedded in a matrix, which matrix contacts with the cementitious facing and protects the particles therefrom.

, An' insulating structure comprising a ne'zaoao hase, a hardened cernentitious facing aerent thereto, and corkhoard over the taci and in contact therewith the corkboard constituting particles of cor those particles in the corkboard adjacent the cementitious facing being embedded in an asphaltic matrix, which asphaltic matrix contacts with the cementitious facing and protects the particles therefrom. il@ 8. ln the method of erecting corkboard treated to prevent attack by plaster, the steps .consisting in applying a coating of wet limecontainin plaster to the surface of the board, placing t e `hoard against a base with the 35 coating in contact with the base and supporting the board in position until the plaster hardens.

9. ln the method of erecting corklooard treated to prevent attack by plaster, the steps consisting in securing a hanger to the board, bedding the projecting portion o' the hanger in a coating of Wet plaster spread over the surface of the board, placing the board against a loase while the plaster is Wet and maintaining it in Contact with the hase While the plaster hardens.

ln testimony whereof ll have hereunto set rn hand.

y f vriLES (32W: 

